GX16 and GX20 are two of the most widely used circular aviation connector series in industrial equipment, robotics, and automation. For buyers sourcing replacement pins or planning custom connectors, the difference between these two sizes matters — not just in diameter, but in pin capacity, current rating, and machined contact geometry. This guide compares GX16 vs GX20 connector pins so you can specify the right one for your application.

GX16 vs GX20 Connector Pins | Spec Comparison for Custom Machined Contacts

Direct answer: VOLCRIX supplies custom GX16 and GX20 connector pins as bar turned components for electronic connectors, machined from brass C3604, C26000, or tellurium copper C14500. Both series share M×0.75 thread and solder-cup terminations, but differ in shell diameter, current rating, and pin count. We hold ±0.01 mm on contact OD with 0.4 µm Ra on the engagement zone. Send your drawing to our quoting form, or WhatsApp us at +86 188 6828 5255.

GX16 vs GX20: The Basics

The deciding factor for most buyers is the combination of rated current and pin count. If you need more than 7 pins or more than 10 A per pin, GX20 is the only realistic option. If your connector is 5-10 A and 2-7 pins, GX16 fits and saves roughly 30% on shell cost.

Common Applications for GX16 and GX20 Connector Pins

GX16 and GX20 are the workhorses of industrial circular connectors. The four bar turned components for electronic connectors applications we run most often at VOLCRIX:

• Industrial robotics and CNC machine tool feedback. GX16 pins in 4-pin and 5-pin configurations for encoder feedback, servo motor resolvers, and limit-switch wiring on CNC machines, robotic arms, and automated assembly cells. Threaded lock prevents vibration disconnect.
• Automation controller signal wiring. GX20 pins in 7-pin and 9-pin configurations for PLC I/O blocks, distributed control systems, and sensor harnesses. Rated 25 A per pin suits solenoid valves and small motor drives on the same harness.
• Test and measurement equipment. GX16 pins in 2-pin and 3-pin configurations for multimeter probes, oscilloscope leads, bench-top power supply outputs, and laboratory test fixtures. Solder-cup termination suits short-run test leads.
• Audio, broadcast, and stage equipment. GX16 and GX20 pins for balanced audio XLR-style fan-outs, DMX lighting control, and broadcast camera interconnects. Brass pin with gold plating (0.5–1.0 µm over nickel 1.5 µm) is standard for low-noise audio contacts.

Manufacturing Support from VOLCRIX for GX16 / GX20 Pins

When a GX16 or GX20 pin drawing lands on our engineering desk, we check whether it is stock geometry or proprietary. Stock pins run on Star SR-20 with standard tooling; proprietary pins need full tool build and PPAP. Here is what we deliver on every program:

• Material selection for signal and power pins. Brass C3604 (free-machining, best for high-volume signal pins); C26000 (cartridge, better for crimp); tellurium copper C14500 (90% IACS, higher current); phosphor bronze C54400 (spring temper, female socket contacts). All materials ship with mill cert per EN 10204 3.1 and incoming spectrometer check on Bruker Q4 Tasman.
• Star SR-20 and SR-20R Swiss turning with sub-spindle. For GX16 and GX20 pins we run Star SR-20 / SR-20R Swiss turning machines with sub-spindle pickoff. Main-spindle ±0.005 mm; sub-spindle ±0.01 mm for closed-end crimp zone. Cycle times 8–25 s per pin.
• Solder-cup, crimp, and screw terminations in one setup. We can combine multiple termination styles in one pin — solder cup on one end, screw thread on the other — by adding secondary milling or threading on the SR-20R sub-spindle. This avoids a separate op and keeps the pin concentric within ±0.01 mm.
• Plating options for contact and corrosion performance. Gold 0.5–1.0 µm over nickel 1.5–2.5 µm for low-level signal/audio (ASTM B488); tin 5–8 µm over copper flash for solderable terminations (ASTM B545); silver 3–5 µm over nickel for higher-current pins (ASTM B700). Thickness verified on Fischer XDLM XRF.
• 100% pin inspection and batch Hi-Pot testing. Each lot is verified on Zeiss Contura CMM (pin OD, length, thread profile), 100% continuity-checked, and Hi-Pot tested at 1000 V AC for 60 s on request. Cpk ≥ 1.33 reported on critical features. FAI per AS9102.

GX16 / GX20 Connector Pin Buyer Checklist

Four items to confirm before sending your bar turned components RFQ:

• Confirm the pin count and the rated current per pin. This decides GX16 (5-10 A, 2-7 pins) or GX20 (10-25 A, 2-12 pins). If between the two, GX20 with smaller pin diameter and derated current is often safer — it leaves room for future current upgrade without changing the connector housing.
• Specify the mating connector series. GX16 and GX20 are not pin-compatible — a GX16 pin will not seat in a GX20 socket. Confirm the mating connector brand and series (e.g. “compatible with GX16-4 Binder 581” or “GX20-7 Hirschmann CA-Series”) so we can validate geometry against published datasheets.
• Specify plating stack and thickness. Gold over nickel for signal/audio, tin over copper flash for solder terminations, silver over nickel for power. The spec should be explicit (e.g. “Au 0.75 µm min over Ni 2.0 µm min per ASTM B488”).
• Plan for vibration and locking torque. GX16 and GX20 use a threaded locking ring. Specify the locking torque range (typically 0.5–1.5 N·m for hand assembly, up to 3 N·m for tool-tightened vibration environments).

Authority Summary

Related Custom Manufacturing Services

• Aviation Connector Pins | Custom Machined Contacts — aerospace-grade MIL-DTL-38999 and GX series contact pins
• Custom Electronic Contact Pins — signal-level and power contact pins for industrial connectors
• MIL-DTL-38999 Contacts vs GX Series Pins — aerospace vs industrial connector pin comparison

Frequently Asked Questions

Certifications & Standards